27 Powered Industrial Truck Safety
1 PITS and Their Purpose
2 Maintenance and Inspection
3 PIT Operation Basics
4 PIT Operating Hazards
5 Safety Training Requirements
1 PITS (Powered Industrial Trucks) and Their Purpose
A PIT is a mobile, power- propelled truck that is equipped to: Carry – Push – Pill – Lift - Stack – Tier
PITS are essential equipment on many job sites and are commonly referred to as forklifts or lift trucks. They can
be ridden or controlled by a walking operator.
Who Can Operate a PIT?
- Only trained and authorized workers are permitted to operate a forklift even for very small job part.
- Your employer is responsible for training you on the specific types of forklifts you will use or encounter
in your job.
Course Scope: this course will cover general awareness information and safe operation practices and it is not
intended to deliver authorized qualified or person training. It will cover rough terrain fork trucks used on
construction sites. It cannot provide operational training because unique characteristics of forklifts, which vary
by vehicle type and manufacturer.
Electric-Powered Forklifts: PITS have rechargeable industrial batteries that power an electric motor. It is use
when exhaust is a concern,( no harmful emissions and much quieter)
Electric Powered fork Truck: is commonly used indoors on smooth, hard surfaces. Its quiet operation and lack of
emissions make it ideal for operation in enclosed areas.
Stand-UP Fork Truck: is designed for applications where the operator must frequently get on and off the truck,
the operator stands in the cab while operating. It and enters and exits from the rear.
Order Picker Fork Truck: operators ride an order picker, which can lift them as high as 32 feet (9.7m), to
retrieved items from storage racks and place them on the machine’s carry deck. These PITS are designed for
storage facilities, narrow aisles, and small warehouses.
Yard Fork Truck: The yard fork truck has large, pneumatic tires and is used outdoors on both smooth and rough
surfaces, but is not considered and all terrain vehicle.
Reach Truck: the electric reach truck is used for high tiering, which involves storing material in multiple tiers
high off the ground. It is commonly used in a warehouse to stack palletized goods or to lift palletized materials.
Electric Transtacker: The electric transtacker is an indoor, warehouse specific vehicle that allows the operator to
high-tier stack loads on upper level of narrow aisle storage racks.
Electric Walk-Behind or Ride-on Pallet Jack: the electric walk-behind or ride-on pallet jack is often called a “
walkie” because it is a type of motorized pallet truck that the operator must walk behind or alongside. It is used
to transport products over short distances and lift pallets where a traditional forklift is not necessary.
Forklifts Powered by Internal Combustion Engines: PITS can also be powered by internal combustion engines
that run on a variety of fuels, including gasoline, diesel fuel, liquid petroleum gas, and compressed natural gas.
They cannot be used for long periods of time in a confined area without adequate ventilation.
Gasoline-Powered Fork Truck: is used for both indoor and outdoor application. Pneumatic tires enable this fork
truck to operate on smooth and rough surfaces.
Propane-Powered Fork Truck: can be used both indoors and out. While propane engines are noted for low
emissions, care must be taken when operation in enclosed areas to prevent exhaust fume buildup.
Diesel Large Port Terminal Fork Truck: is a high- capacity vehicle used for loading, moving and unloading cargo
from ships transiting through freight terminals.
Vehicle Selection: always consider your task and working environment before selecting a PIT.
PIT Characteristics: the rear wheel steering of a forklift enables it to make tight turns, but it also causes the rear
to swing wide, presenting a striking hazard in narrow spaces.
A forklift and a motorized pallet truck can lift and transport a load, however, because a forklift can lift a larger
load to greater heights, the inherent hazard of tip over is much greater when using a forklift than it is when
using a pallet truck.
A forklift and pallet truck can load or offload a trailer, but a forklift weighs significantly more and may exceed
the floor rating of the trailer.
Operating any type of forklift with an internal combustion engine in an enclosed space, such as trailer, presents
the risk of exhaust gas buildup.
2- Inspector General:
Proper maintenance, refueling, and recharging of forklift contribute to the safety of all employees.
Maintenance and Recharging: just like automobiles, the forklifts in your workplace require scheduled
maintenance to remain in good working order, this critical practice prevents mechanical issues that might affect
forklift operation and possibly lead to an injury or accident.
Do not attempt: repairs unless you are authorized – trained personnel must perform maintenance according to
the manufacturer schedule.
To use a forklift that has been removed from service until maintenance has been completed and the problem is
resolved.
Recharging Procedure: battery powered vehicles require routine charging.
Only trained personnel should: charge batteries – change batteries
These employees must also be trained on emergency procedures in the event of an acid spill or contact with the
body, including how to use eyewash and shower facilities.
Recharging Area: There must be a designated safe area for battery changing and charging. This area must
contain equipment to minimize the hazards associated with sulfuric acid and hydrogen gas, both of which are
present where batteries are stored. Charged, and maintained.
There should be: clearly visible posted signs that warn of hazards and remind workers not to smoke in the area.
- A water supply for flushing and neutralizing spilled electrolyte
- An eyewash station and for larger facilities, a safety shower.
- Acid neutralization materials in the immediate area
- An appropriately rated fire extinguisher
- Adequate ventilation to prevent the buildup of hydrogen gas during battery charging.
- A telephone or other means of communication for use in the event of an emergency.
Refueling: only trained personnel should refuel forklift that use liquid petroleum gas, like propane forklifts. As a
vehicle operator , you are responsible for refueling your forklift only if it is powered by gasoline or diesel internal
combustion engine.
Correct Refueling Procedures:
- Never smoke while refueling
- Do not fill the tank to the top
- Park the forklift in the designated refueling area
- Place the transmission in neutral and lower the forks to ground
- Engage the parking brake
- Open the filler cap. Fill the tank slowly. And close the cap
- If spillage occurs wipe off the fuel and wash down the area with water.
PIT Inspection Requirements: Just as regularly schedule maintenance is a priority, routine inspections are critical
as well:
Inspection Frequency: inspect your forklift before each shift, as required by your employer.
Conduct a pre-operational inspection before you enter the vehicle
Conduct an operational inspection after you start the engine
A through inspection process is vital to ensure proper and safe performance of the forklift. Report any issues tp
your supervisor right away. Depending on how serious the issue is, your supervisor may choose to address it
immediately or remove the forklift from service until qualified personnel can address the issue.
Remove a PIT from Service:
Issues that indicate you should stop operating your vehicle include: mechanical breakdown – smoke – fire unusual odors or sounds – overheating – leakage
If any of these issues occur, you must return all load handling controls to a neutral position and, if safe to do so,
shut down the vehicle and immediately report the issue to your supervisor.
Always follow your company procedures and the forklift manufacturer recommendations.
General Pre-Operational Inspection:
Load handling Devices: inspect the condition of any components that will support and carry a load, including
the: forks – platforms – mast – chains – cables – pulleys – backrest extensions.
Look for Leaks crack and defect in the hoses or lines
Ensure tires inflated to the recommended pressure indicated on the tire sidewall – in good repair
Operator compartment: ensure it is clean and free of grease, dirt, oil
Seabelt horn backup alarm warning beacons and lights are operational.
Data specification plate and manufacturer safety decals are not missing or obscured
Operator manual is onboard and properly stowed
Vehicle is equipped with a fire extinguisher that it is ready to use.
Check all fluid levels, including fuel – oil – hydraulic fluids – coolant
General Operational Inspection:
After completing the pre-operational inspection, enter the cab and check the following:
Accelerator linkage – with the parking brake applied in neutral, make sure that the accelerator control and
linkage moves freely and returns to a neutral position when released.
Inch control - ensure the “inching pedal”, which allows for slow, controlled, movements is operational ( of
applicable)
Brakes – apply and watch for low brake pressure and excessive pedal travel
Steering – ensure there is no “play” in the steering linkage and that the wheel turns without binding or
hesitation.
Load handling attachments: ensure smooth operation, adequate hydraulic pressure, and no leaks
Horn – check that it is operable (if equipped)
Hour meter – make sure that it is running
Lights – verify all running, cargo, back up lights, and safety beacons work; a spotter may assist
Backup alarm – with the parking brake applied, place in reverse and verify it is audible (if present)
Safe Practices:
Before You Drive – Mind your speed – Travel safely (safe distance 3 vehicle) – Watch for obstructions ( ramp 45
degree) – Change direction Carefully – Turn and steer Wisely
Lifting and lowering Hazards: before you lift a load, ensure that there is adequate clearance between the load
and surrounding structures to prevent the load from falling or becoming stuck and causing damage to the load
or racking.
When lowering or placing a load, ensure that: you place the load in a stable position – the load surface has
adequate capacity – the fork tines and mast will not strike surrounding structures.
Trailer and Railroad car Hazards: when loading or unloading trailers and railroad cars
- Keep a clear view and use a spotter when necessary to avoid falling over the edge of a loading dock
- Make sure that the trailer and rolling stock wheels are blocked and that the driver or engineer is aware
of your position to prevent trailer or railroad car movement during load handling
- Ensure deck plates are secure and sufficient for the weight of your vehicle
- Ensure that the trailer or railroad cars floor is rated to support your vehicle and its load
- Make certain that the trailer opening can accommodate your forklift mast (if equipped) when extended
to allow for travel and load handling, and be certain that the mast is not extended further than needed
- Be aware of others working in and around the trailer and announce your entrance and exit by sounding
your horn.
High Tiering: is a method of stacking materials in multiple tiers high off the ground. A reach truck is often used
for this operations.
To avoid overloading and tip over, follow these practice:
- Set the heaviest loads on the bottom, tier
- Reduce the load below the capacity of your reach truck as the mast is fully extended
- Slowly and carefully extend the reach mechanism forward when stacking loads
- Use extreme care when tilting a load forward or backward
Parking You PIT
Introduction: if you are 25 feet (7.6m) or frther from your forklift, it becomes an unattended vehicle – even if it
remains in your view.
Unless it is properly secured an unattended vehicle can
- Be accidentally struck by other vehicle
- Move unintentionally and become danger
Step1: select a hard level surface in an authorized parking area. If you must park on an incline, block the wheels
to prevent your forklift from moving . do not block traffic, and it can be seen
Park a safe distance from: fire lanes - fire equipment – stairways
Step 2: after coming to complete stop fully engage the parking brake
Step 3:Set down your load: if carrying a load, lower the load handling mechanism fully so that the load is resting
on the ground.
Step 4: completely neutralize your forklift control by: setting the transmission or direction lever in neutral
Titling the mast forward slightly so that the fork tips are in contact with the floor
Step 5 : Shut down and exit. Stop engine of off and remove the key, exit carefully.
Step 6 : Special Consideration: park only in authorized area except disabled. If unable to lower load handling due
to disabled, follow your facility lock out/tagout procedures and not allow anyone to pass
If you are within 25 feet, follow parking procedures and vehicle remain in your view and not required to shut
down the engine or turn power off
4 PIT Hazards Operating
Tip Over: minimize hazard of a tip by knowing the basics of a forklift stability triangle.
Center of Gravity: it is the point on an object at which all of it weight is concentrated. For symmetrical loads
the center is at the middle of the load relative to load length, width, and height
Forklift stability is based on keeping the center of gravity inside the stability triangle. The vehicle is
supported at two front wheels and at the center of the steer axle. When center falls within the triangle it is
safe to drive.
Loading: no load the center is precisely inside the stability triangle. With load the center shifts closer to the
front axle.
Once reaches the front axle, it is edge of center and load becomes unsafe to carry. With every type of PIT
the rule center of gravity should be inside the stability triangle.
Tip Over Hazards:When a PIT tips over because center of gravity outside stability triangle or wheel base, it usually tips forward
or to the side due to different reason
1- Improper loading: a load weight distribution changes the handling performance of the forklift and the
amount of weight a forklift can safely carry.
Ensure that: Handle load that are within the capacity of the forklift as stated on the data plate or
operator manual
Load the heaviest weight at the bottom and as close to the mast as possible
Travel with mast tilted back to stabilize the load
Distribute the weight evenly when carrying irregularly sized loads
2-Carrying a load too high: never travel with an elevated load because it is making the forklift and load less
stable. So keep the load as low to the ground and close from front wheel by carrying in lowest position about 4
to 6 inches (10 to 15cm) from the ground.
2- Braking too hard: keep speed under control and do not brake suddenly.
4- Turning with an elevated load: lower your load before turning to not lose stability.
5-Road Hazards: Potholes, debris, and other road hazards can lead to unexpected tip over. So inform safety
manger about any hazards in workplace.
In Case of TIP Over: never attempt to jump out in the process of tipping over.
Safety features: most forklifts have a metal cage or roll-over protection system (ROPS) and with seatbelt work
together to keep you safe. Some old models lacks this equipment, it is important to stay within the vehicle and
brace yourself for impact.
1- Grip the steering Wheel and use it as upper body support to absorb the initial impact.
2- Use your feet to brace yourself
3- Lean away and in the opposite direction of the fall to minimize your risk of suffering an injury.
4- Stand up, rear-entry forklift are most likely to tip forward. The standard procedure is to step backwards
from the cab and remain clear of the vehicle
Workplace Condition:
1- Ramps and Grades: always keep your load upgrade, regardless of your direction of travel.
In traveling up an incline: drive with loaded forks pointed upgrade and use a spotter if load blocks
your view
When traveling down: drive in reverse with loaded forks pointed upgrade and turn your head and
face downgrade.
When traveling without a load, the forks should point down the incline regardless of the direction of
travel.
2- Loading Docks: observe posted speed limits, watch for other, and be aware of the docks edge
(painted for visible). In Wet or slippery conditions require additional caution and dock plates are
properly secured and in good condition and meet the required capacity.
3- Pedestrian Traffic: always remain alert for pedestrians and workers in or near your path.
4- Obstructions: make sure you know the overall height of your forklift with the forks in the travel
position. Look for overhead obstruction. Any striking obstruction can damage that equipment and
vehicle and cause injury.
5- Enclosed/Hazardous Areas: be aware of exhaust and carbon monoxide buildup with an internal
combustion powered forklift in enclosed area such as a trailer. Only use designated one for
hazardous locations.
6- Slippery Conditions: such as oil, grease or water can cause skid. And ice, snow, mud, and gravel for
uneven surface can lead to a tip over. Drive slowly in that condition and report to warn others.
Pedestrian Traffic: the roles
Operator’s Responsibility:- be aware of pedestrian traffic and remember they can be unpredictable.
You need to make sure: always yield to pedestrians – drive slowly – sound the horn for limited vision –
use a spotter for blind spots – never allow anyone to walk underneath the load – make eye contact –
signal my intentions.
Pedestrian’s Responsibility: stand clear of a forklift – recognize that operator have limited visibility and
make eye contact – be aware for wide rear-swing radius – never walk underneath load- never try to
catch a ride on a forklift.
Plant Safety Manager: protect pedestrian walkways with permanent railings or protective barriers
where needed. Clearly marked pedestrian walking lanes with stripping on the floor. Adequate walking
space on at least one side in case use equipment aisles. Traffic control sign where needed.
Operator Fitness and Focus:
To be Authorized Operation: at least 18 years – trained – certified and don’t apply to certain agricultural
operations. You need certified on each vehicle you may use.
Impairment: when sick or medication and when doubt, inform supervisor you may be unable to safely operate
any vehicle.
Distractions: you need to be full concentration so, you may cause harm if you use headphones – cell phone –
other nonessential devices.
Equipment misuse: you can cause an accident if you transport passengers – use the wrong vehicle – travel with
a load elevated high.
5- Safety Training Requirements:
Operator Training:
Formal Training: forklift operator must pass a written test after receiving formal instruction that can include
training methods such as Lectures – Discussions – Interactive computer learning – Videos – Written material.
Practical Training: Practical test for powered industrial trucks after they receive hands=on training.
Certification: employers must certify that each operator has been trained and evaluated. Certificate include
operator name, trainer name, and the training and evaluation dates.
Refresher Training: including an evaluation, must be conducted at least once every three years to ensure that
the operator has knowledge and skills needed to operate a PIT safely.
The refresher training is required when an operator: when operating in an unsafe manner – involved in an
accident or near miss incident – assigned to drive a different type of truck – when a condition in the workplace
changes that affect the safe operation of the truck.
PIT Safety Training Program: to get effective training your employer must develop and implement it based on
the: general principle of safe forklift operation – types of vehicles – hazards of the workplaces – general safety
requirements.
You should continue to watch for:
PIT related hazards in your workplace – opportunities to improve the safety of yourself and your coworkers.
4 PIT